Rubber Bales and Apparatus and Method for Making Same

ABSTRACT

Improved bales may be formed using methods that include baling equipment with multi-component bolster assemblies that may ease installation and removal, reduce wear and tear and maintenance, and/or improve efficiency by reducing material waste, imperfections, and/or contamination. The bolster assemblies may include a plurality of coupling portions that engage a hydraulic rod and may enable the bolster assembly to self-center within a press chamber during normal baling operations. The bolster assemblies also may include an island portion that may be attached to the coupling portions and to a bolster cap, and the latter may be attached using retainer bolts having substantially flat, non-circular heads. The bolts may reduce irregularities in the bale and/or prevent material seepage into the bolster assemblies. During maintenance, an operator may remove only the bolster cap island assembly for cleaning, substantially reducing the time and strength needed to clean and/or repair the baler and reduce downtime.

BACKGROUND OF THE INVENTION 1. Technical Field

The present invention relates to rubber bales and baling equipment, andmore particularly to a reduced-maintenance rubber baler having amulti-component bolster cap.

2. Related Art

Rubber is a notoriously difficult material to handle. It also must behandled with care, taking into consideration its various intended uses,some of which are for food or pharmaceutical grade rubber. Especiallyfor the latter purpose, contamination must be avoided. A change ofproduct may require complete cleaning of equipment, sometimes requiringdisassembly, particularly of balers.

Color, which may be white or transparent, must be considered.

Irregularities such as “teats” remaining on the outer surfaces of balesafter forming at high pressure—the teats corresponding to small holes orcrevices in the baling machine—are undesirable but inevitable asartifacts of the baling process. Sometimes teats break off in themachine and remain lodged there for several cycles, transforming incolor from white to gray, and then sometimes coming loose and beingmolded into a bale which is then ejected with a discolored teat, whichcan result in rejection of the bale, especially in pharmaceutical gradesand the like. Maintenance is demanding. Heavy pieces of equipment mustbe maneuvered in tight, crowded spaces. Each second of downtime is lostprofit.

After synthetic rubber is dried in large sheets, it is crumbled andbaled. The pieces are larger—some of them becoming fused together—orsmaller with a great deal of dust—all of which is desired to be formedinto bales. The crumbles may vary in size depending on their Mooneyrating. For example, dry, low Mooney crumbles may be between about thesize of talcum powder or dust to about the size of a walnut, while wet,sticky, high Mooney crumbles may be between about the size of a walnutto about the size of an orange. The mess of dust can fall back in,contaminating the next batch in the run and forming irregularities.Irregularities and material waste are another concern that may becaused, for example, by misalignment of a bolster. Material seeps out ofthe compression zone, clogging the press chamber, creating a bind forthe ram, increasing service time, decreasing profits.

Prior art assemblies also use large, heavy ram head assemblies(typically exceeding 550 lbs.) to compress the compressible materialsduring bale formation. These ram head assemblies include large baseportions placed over the end of a hydraulic rod that are held in placeby a large pin placed through apertures in the base, the rod, andopposite side of the base (similar to the pins used to keepoutdoor/table umbrellas open). Those pins are susceptible to breaking,causing damage to the ram as well as scarring of the hydraulic cylindershaft surface which may cause premature seal failure of the hydrauliccylinder and/or misalignment. Misalignment creates greater side pressureon one side of the ram head as compared to the other side. The unevenside pressure causes excessive wear on the side seeing the mostpressure, reducing the useful life of the ram head. Additionally, theheavy assemblies are difficult to change in the cramped quarters, oftenrequiring a crane or other equipment.

Finally, the bolts used in prior art ram assemblies to secure a bolstercap include center indentions. These indentations can cause baledeformation and/or contamination when remnants of prior batches getstuck in the indentation. For example, black rubber used for tires maycontaminate clear or white rubber used in pharmaceuticals.

Improvements such as the bolster or bolster assembly described incommonly assigned U.S. Pat. No. 5,870,951, the entire disclosure ofwhich is hereby incorporated by reference, have helped to reducematerial waste from about 600-1000 lbs. of waste per 24 hours to about40-80 lbs. of waste per day. However, a need has long existed for evenfurther improved systems and methods for rubber baling.

SUMMARY

Improved bales may be formed using methods that include baling equipmentwith multi-component bolster assemblies that may ease installation andremoval, reduce wear and tear and maintenance, and/or improve efficiencyby reducing material waste, imperfections, and/or contamination. Thebolster assemblies may include a plurality of coupling portions thatengage a hydraulic rod and may enable the bolster assembly toself-center within a press chamber during normal baling operations. Thebolster assemblies also may include an island portion that may beattached to the coupling portions and to a bolster cap, and the lattermay be attached using retainer bolts having substantially flat,non-circular heads. The bolts may reduce irregularities in the baleand/or prevent material seepage into the bolster assemblies. Duringmaintenance, an operator may remove only the bolster cap island assemblyfor cleaning, substantially reducing the time and strength needed toclean and/or repair the baler and reduce downtime.

Other systems, methods, features and technical advantages of theinvention will be, or will become apparent to one with skill in the art,upon examination of the figures and detailed description. It is intendedthat all such additional systems, methods, features and technicaladvantages be included within this summary and be protected by theclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the invention.

FIG. 1 shows a side cross-sectional view an exemplary baler pressassembly;

FIG. 2 shows an exploded view of an exemplary bolster assembly for usein a rubber baler;

FIG. 3 shows a side cross-sectional view the exemplary bolster assemblyof FIG. 2 mounted on an exemplary hydraulic rod;

FIGS. 4A-B show a perspective view and a bottom view of an exemplaryisland portion of the exemplary bolster assembly of FIG. 2;

FIGS. 5A-B show a perspective view and a cross-sectional view of anexemplary bolster cap of the exemplary bolster assembly of FIG. 2;

FIGS. 6A-B show a side view and a top view of an exemplary retainer boltfor use with the exemplary bolster assembly of FIG. 2;

FIGS. 6C-D show a cross-sectional view and a top view of an exemplarylifting retainer bolt for use with the exemplary bolster assembly ofFIG. 2;

FIG. 6E shows a perspective view of an exemplary retainer bolt for usewith the exemplary bolster assembly of FIG. 2;

FIGS. 7A-C show top, side and bottom views of the exemplary bolsterassembly of FIG. 2 in an assembled configuration;

FIGS. 8A-B show perspective views of exemplary rubber bales formed usingthe exemplary bolster assembly of FIG. 2;

FIGS. 9-12 show side and perspective views of the exemplary baler pressassembly of FIG. 1 at various stages of a bale forming process; and

FIG. 13 shows a perspective view of an exemplary crumb box and coverassembly for use in the exemplary baler press assembly of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The elements illustrated in the figures interoperate as explained inmore detail below. Before setting forth the detailed explanation,however, it is noted that all of the discussion below, regardless of theparticular implementation being described, is exemplary in nature,rather than limiting.

1.0 Baler Assembly Overview

Referring to the drawings, and initially to FIG. 1, a side view of anexemplary upstroke baler press assembly 10 is shown. Only relevantportions of the baler press assembly 10 are shown; other portions arewell known to those skilled in the art and are not discussed herein forsake of clarity. In the illustrated embodiment, the baler press assembly10 may include a press chamber 100, a bale ejector assembly 200 and aram assembly 300. The press chamber 100 may include press walls 110 thatfunction to provide a rigid support capable of withstanding at least thecompression forces necessary to form the bale (described below inSection 3.0). Press wall liners 120 may be secured to the inside of thepress walls 110, such as by means of socket cap screws. Other types ofsecuring mechanisms also may be used in place of the socket cap screws.

The ram assembly 300 may include a hydraulic rod 302 positioned within arod housing and scraper 304. A bolster assembly 308 may be secured tothe end of the hydraulic rod 302. Hydraulic power from the power unitmay be supplied to the baler press assembly 10 at a number of powerconnection points.

2.0 Exemplary Bolster Assemblies 308

Referring now to FIG. 2, an exploded view of an exemplary bolsterassembly 308 is shown. The bolster assembly 308 may include a firstcoupling portion 310 a and a second coupling portion 310 b that coupleto one another, the hydraulic rod 302 and an island portion 320. Inturn, the island portion 320 may couple to a bolster cap 330.

The various components of the bolster assembly 308 may be made of anysuitably hard material, such as metal, a thermoplastic polymer, or thelike. As used herein, the term “thermoplastic polymer” is defined toencompass the DuPont materials Delrin® and Delrin AF® and any othermaterials having similar relevant properties. Delrin® is an acetal resinthermoplastic polymer (or acetal homopolymer) manufactured by thepolymerization of formaldehyde. Delrin AF® contains high tensilestrength fibers of Teflon® fluoroplastic resin. Similar wear resistantmaterials having low static and dynamic coefficients of friction (ascompared to steel) and capable of being formed into or bonded to presswall liners and bolster caps are considered to fall within the scope ofthe term thermoplastic polymer as used in the claimed invention. Othermaterials also may be used. In some embodiments, each component is madeof the same material. Alternatively or additionally, one or more of thecomponents of the bolster assembly 308 may be made of different materialthan others of the components.

2.1 Exemplary Coupling Portions 310

Referring also to FIG. 3, each of the coupling portions 310 a and 310 bmay include a lower portion 311 and an upper portion 312. When thecoupling portions 310 a and 310 b are coupled to one another, theirrespective lower portions 311 a and 311 b and upper portions 312 a and312 b may defines cavities for receiving corresponding portions 305 and306 of the hydraulic rod 302. This unique configuration provides severalbenefits over the prior art assemblies, such as increased machinereliability, reduced maintenance, and/or an extended machine life.

In some embodiments, the cavities defined by the lower portions 311 aand 311 b and upper portions 312 a and 312 b may be about the same sizeas the corresponding portions 305 and 306 of the hydraulic rod 302.Preferably, the cavities defined by the lower portions 311 and upperportions 312 a and 312 b may be larger than the corresponding portions305 and 306 of the hydraulic rod 302. For example, in a horizontaldirection, the cavities defined by the lower portions 311 a and 311 band upper portions 312 a and 312 b may be between about 0.025 inches andabout 0.040 inches larger than the corresponding portions 305 and 306 ofthe hydraulic rod 302, preferably between about 0.030 inches and about0.035 inches larger than the corresponding portions 305 and 306 of thehydraulic rod 302. Similarly, in a vertical direction, the cavitiesdefined by the lower portions 311 a and 311 b and upper portions 312 aand 312 b may be between about 0.002 inches and about 0.010 incheslarger than the corresponding portions 305 and 306 of the hydraulic rod302, preferably between about 0.005 inches and about 0.007 inches largerthan the corresponding portions 305 and 306 of the hydraulic rod 302. Byproviding a larger cavity, the coupling portions 310 a and 310 b mayallow the bolster assembly 308 to self-center in the pressure chamberduring operation. As a result of the coupling portions 310 a and 310 b,preferably no portion of the bolster cap 330 comes into frictionalcontact with the press wall liners 120 during a baling cycle.

Self-centering of bolster assembly 308 may reduce and/or eliminate anyor all misalignment problems and provide at least one or more of avariety of benefits. For example, self-centering may result in extendedlife of those components of the hydraulic cylinder that may experiencewear from frictional engagement between a bolster and a press chamberwall or liner. Because of the self-centering action of the bolsterassembly 308, the amount of side pressure exerted on the hydraulic rod302 packing and seals may be reduced. As a result, the baler pressassembly 10 may have improved reliability when compared to the priorart. The unique design also may improve the useful life of the bolstercap 330 due to potential misalignment of the hydraulic rod 302.

In the illustrated embodiment, the cavities defined by the upperportions 312 a and 312 b and lower portions 311 a and 311 b of thecoupling portions 310 a and 310 b may comprise toroids, andspecifically, rectangular toroids. In other words, the upper portions312 a and 312 b and lower portions 311 a and 311 b each definerespective arcs that form cylindrical cavities when the couplingportions 310 a and 310 b are attached to one another. Other shapes mayalso be used. In addition, although two coupling portions 310 a and 310b are shown, more or less coupling portions may be used.

The coupling portions 310 a and 310 b may be coupled to one another viabolts disposed in apertures 316. Alternatively, or additionally, othermethods may be used to secure coupling portions 310 a and 310 b to oneanother. In addition, coupling portions 310 a and 310 b may be movablyattached to one another. For example, coupling portions 310 a and 310 bmay be hingedly attached to one another on one end and a single bolt maybe used to fix the coupling portions 310 a and 310 b about the hydraulicrod 302. Other variations also may be used.

2.2 Exemplary Island Portions 320

Referring to FIGS. 4A-B, an exemplary island portion 320 is shown inboth perspective and bottom views. The island portion 320 may include areduced section 322 and a base 328. The reduced section 322 may alsoinclude a plurality of bores 326 for receiving bolts that attached theisland portion 320 to the coupling portions 310 a and 310 b. In theillustrated embodiment, six bores 326 are provided to receive the bolts.The island portion 320 also may include a plurality of bolster bores 322for receiving the retainer bolts 334 and 336 used to attach the bolstercap 330. The island portion 320 may weigh between about 160 lbs. andabout 220 lbs., preferably may be between about 175 lbs. and about 205lbs., and even more preferably between about 190 lbs. and about 195 lbs.This is a significant reduction in weight from the prior art, resultingin eased maintenance.

2.3 Exemplary Bolster Caps 330

Referring to FIGS. 5A-B, an exemplary bolster cap 330 is shown inperspective and cross-sectional views. In the illustrated embodiment,the bolster cap 330 may include a recessed portion 337 that may beconfigured to receive the reduced section 327 of the island portion 320.The bolster cap 330 may weigh between about 20 lbs. and about 60 lbs.,preferably may be between about 30 lbs. and about 50 lbs., and even morepreferably between about 40 lbs. and about 45 lbs. In addition, thebolster cap 330 may include a plurality of countersunk bores 332corresponding to the bores of the reduced section of the bolster 322.The countersunk bores 332 and bores 322 may be adapted to receiveretainer bolts 334 and/or a lifting retainer bolt 336.

2.3.1 Exemplary Retainer Bolts 334

A novel exemplary retainer bolt 334 is shown in a side view, a top viewand a perspective view in FIGS. 6A, 6B and 6E, and an exemplary liftingretainer bolt 336 is shown in a cross-sectional view and a top view inFIGS. 6C-D. The retainer bolt 334 and the lifting retainer bolt 336 mayhave generally the same overall shape. For example, the retainer bolt334 and the lifting retainer bolt 336 may each include substantiallyflat heads 340 and 350, frustoconical portions 342 and 352, unthreadedportions 344 and 354, and threaded portions 346 and 356. The bolts 334and 336 also may include a center drill hole 349 (FIG. 6E) that is usedto provide a consistent center during machining of the bolts 334 and336. The retainer bolts 334 and lifting retainer bolt 336 may be made ofany suitable material, such as 316 stainless steel or the like.

Preferably, retainer bolts 334 and the lifting retainer bolt 336 have asubstantially flat head so that the upper surface of the bolster cap 330is substantially flat and even. The use of flat heads may reduce oreliminate the formation of irregularities such as “teats” from formingduring the baling process. In some embodiments, a lifting retainer bolt336 may be provided, such as in the center of the bolster cap 330, tofacilitate removal of the bolster cap 330 and island 320.

In some embodiments, the retainer bolts 334 and 336 may be placed incountersunk bores 332 (also referred to as pockets) in the bolter cap330, run through the island 320 and be secured by a corresponding nut360 and locking washer 362. Optionally, adhesives, such as LOCTITE®adhesives sold be Henkel North America of Rocky Hill, Conn., may be usedto further secure the bolts 334 and 336 to the corresponding nuts 360.

The countersunk bores 332 may complimentary shapes for receiving thebolts 334 and 336, such as non-circular openings 333, frustoconicalportions, and the like. In the illustrated embodiment, the heads of thebolt 334 are rounded rectangles, and, in particular, rounded squares.Other non-circular shapes also may be used, such as ovals, triangles,hexagons and the like. The use of non-circular openings 333 may preventthe non-circular heads 340 and 350 of retainer bolts 334 and 336 fromrotating while in the bores 332. They also may allow corresponding nuts360 (shown in FIG. 2), which may be a Teflon locking nut or the like, tobe removed from the bolts 334 and 336 without the need for an additionalinstruments (such as a screwdriver) to be inserted into the heads 340and 350 of the bolts 334 and 336.

The size of the heads 340 and 350 may vary based on the shape used.

For example, the rounded rectangular heads 340 and 350 shown in FIGS.6A-D may have sides between about 1¾ inches and about 2¼ inches,preferably about 2 inches, and may have corner radii between about ¼inches and about ½ inches, preferably about ⅜ inches. The roundedrectangular shape may provide a stronger bolt head 340 over a purerectangular head. The depth of the heads 340 and 350 may be betweenabout ⅛ inches and about ⅜ inches, preferably about ¼ inches.

The frustoconical portion of the bolts 334 and 336 may be angled betweenabout 76° and about 88°, preferably between about 79° and about 85°, andeven more preferably about 82°. The frustoconical portions 342 and 352may have heights between about ½ inches and about 1⅛ inches, preferablybetween about ⅝ inches and about 1 inch and in one embodiment about ⅘inches. The diameter of the bases of the frustoconical portions 342 and352 may be about the same size as the sides of the head 340 and 350, orpreferably may be slightly smaller than the sides of the heads 340 and350 so that the lip 341 provided by the underside of the heads 340 and350 may run about the perimeter of the base of the frustoconicalportions 342 and 352. For example, for a retainer bolt 334 having a sideof about 2 inches, the diameter of the frustoconical portion 342 may be1 995/1000 inches.

The combination of the flat heads 340 and 350, angled frustoconicalportions 342 and 352, and/or the lips 341, and their complimentaryportions in the bores 332, may reduce and/or substantially prevent anyrubber crumbles (or portions thereof) from entering the bores 332 and/orsettling between the bolster cap 330 and island portion 320, gumming upthe threads and/or causing bowing between the bolster cap 330 and islandportion 320 over time. In some embodiments, the clearance between thesecomponents 340-42 and their complimentary counterparts in the pockets332 may be between about 1/1000 inches and about 1/100 inches,preferably about 5/1000 inches.

The threaded portions 346 and 356 may have a runout of between about 2¼inches and about 3 inches, preferably about 2½ inches. Various threadingmay be used. Preferably, the threading is fine threading, such as, forexample, ¾ inch 16 UNF threading, ⅞ inch 14 UNF threading, 1 inch 14 UNFthreading, 1⅛ inch 12 UNF threading, or the like. The diameter of thethreaded portion 346 and 356 may be between about ⅘ inches and about 1⅕inches, preferably about 995/1000 inches.

The lifting retainer bolt 336 may include a threaded center bore 338.During bale forming operations, an insert 338 may be inserted into thethreaded center bore 339 to create a substantially flat upper surface.During maintenance (as described below), a handle or other tool may besecured to the threaded portion 339 to allow an operator to lift thebolster cap 330 and island portion 320. Various fine or course threadingmay be used for the threaded center bore 338, such as for example, 7/1614 UNC threading, 7/16 20 UNF threading, ½ 13 UNC threading, ½ 20 UNFthreading, 9/16 12 UNC threading, 9/16 18 UNF threading or the like.

The unique retainer bolts 334 and 336 described herein may reduce and/oreliminate the marring of the under surface of the rubber bale during thebaling operation and/or contamination that may be caused by these priorart bolts. In some embodiments, the bolts 334 and 336 may be tightenedto a predetermined torque rating, such as between about 90 ft./lbs. oftorque to about 150 ft./lbs. of torque, preferably between about 105ft./lbs. of torque and about 135 ft./lbs. of torque and in oneembodiment about 120 ft./lbs. of torque. Tightening the bolts 334 and336 in this range further secures the heads 340 and 350, lips 341 andfrustoconical portions 342 and 352 to the pockets 332, furtherpreventing dust or other compressible materials from infiltrating thebores 332.

2.4 Bolster Assembly/Disassembly

FIGS. 7A, 7B and 7C show top, side and bottom views, respectively, of anassembled exemplary bolster assembly 308. To assemble a bolster assembly308, an operator may position the first coupling portion 310 a and thesecond coupling portion 310 b about the hydraulic rod 302 and secure thecoupling portions 310 a and 310 b to one another via bolts. Next, thebolster cap 330 may be positioned atop the island portion 320 andsecured thereto using the retainer bolts 334. Finally, the combinedisland portion 320 and bolster cap 330 may be positioned atop thecoupling portions 310 a and 310 b and secured thereto by bolts.

Preferably, all frictional contact between the ram assembly 12 and thepress chamber 100 preferably occurs between the press wall liners 120and the bolster cap 330. Thus, the bolster cap 330 receives the brunt ofthe wear for the bolster assembly 308 during baler operation. The designof the bolster assembly 308 allows for the removal of only the islandportion 320 and bolster cap 330 when a bolster cap 330 needsreplacement. This significantly reduces the weight of the removable partof the assembly when compared to the prior art. For example, thecombined weight of the island portion 320 and the bolster cap 330 may bebetween about 180 lbs. and about 280 lbs., preferably may be betweenabout 205 lbs. and about 255 lbs., and even more preferably betweenabout 230 lbs. and about 240 lbs. This weight reduction reduces the timeand physical effort required of the maintenance crew.

2.5 Exemplary Ejector Mechanism

Referring to FIGS. 1 and 9-11, the exemplary ejector mechanism 200 mayinclude a crumb box 210, a cover assembly 220, a cover rail support 230,a cover hydraulic cylinder 240 and a support arm 250. The crumb box 210may provide a pathway for crumbles to enter the press chamber 100 andalso may include an ejection bumper 212 for horizontally ejecting aformed bale 400 (shown in FIGS. 8A and 8B), as described below.

The cover assembly 220 may be attached to the crumb box 210, as shown inFIG. 13. The cover assembly 220 may include a top plate 222, a coverplate 224 and wheels 226. The top plate 222 may close off the crumbleshoot 500 during a bale forming process to prevent additional crumblesspraying onto the baler assembly 10. The cover plate 224 may close thepress chamber 100 during a bale forming operation. The wheels 226 mayallow the cover assembly 220 to move along the cover rail support 230during a bale forming operation.

The cover hydraulic cylinder 240 may provide a motive force for movingthe crumb box 210 and cover assembly 220 during a bale formingoperation. Finally, the support arm 250 may provide a base upon whichthe other portions of the ejector mechanism 200 may rest.

3.0 Bale Forming Methods

Referring to FIGS. 1 and 9-11, during normal operation, rubber crumblesor other compressible materials may be weighed and supplied to the presschamber 100 via a conveyor belt (not shown). As shown in FIG. 9, thecrumb box 210 may be positioned between the crumb shoot 500 and thepress chamber 100 at this time to provide a pathway for crumbles toenter the press chamber 100 to ensure that the full weighed amount ofcrumbles enters the press chamber 100. The crumb box 210 also preventscrumbles from spraying onto other components of the baler assembly 10.

Next, the cover assembly 220 is positioned between the press chamber 100and the crumble shoot 500, as shown in FIG. 10. The top plate 222 mayclose off the crumble shoot 500 at this time to prevent additionalrubber crumbles or other compressible materials from spraying onto thebaler assembly 10. The cover plate 230 may close off the top of thepress chamber, which prevents rubber crumbles or other compressiblematerials from exiting the press chamber. In some embodiments, the coverplate 224 is positioned so as to allow a small gap between the coverplate 224 and the top of the press chamber 100. This gap may allow airto escape from the press chamber 100 during a bale forming operation andprevent the vapor lock and/or the formation of a “fluffy” bale.Preferably, the cover plate 224 is positioned to provide a gap betweenabout 1/100 inches and about 15/1000 inches.

Next, the ram assembly 300 may be activated. Upon activation, hydraulicpower may be applied to the ram assembly 300 such that the hydraulic rod302 travels in an upward direction, forcing the bolster assembly 308into the press chamber 100. The baler press assembly 10 may be poweredby a hydraulic power unit (not shown). The compression force applied bythe ram assembly 300 may be of sufficient magnitude to form a solid baleof the compressible material contained in the press chamber 100. Forexample, the compression force may be between about 1000 pounds persquare inch (PSI) and about 1500 PSI and preferably about 1200 PSI forlow Mooney crumbles. For high Mooney crumbles, the compression force maybe between about 1500 PSI and about 3500 PSI, preferably between about2000 PSI and about 3000 PSI. The dwell time, or duration of thecompression period, may be between about 0.5 seconds and about 3 secondsfor low Mooney crumbles, and in some embodiments about 1 second. Forhigh Mooney crumbles, the dwell time may be between about 10 seconds andabout 20 seconds, and in some embodiments about 15 seconds. Finally, thetemperature of the press chamber may between about 120° F. and about180° F., preferably between about 130° F. and about 155° F., dependingon the type of material.

Following formation of the bale, the ejector mechanism may berepositioned to allow the formed bale 400 to be vertically ejected fromthe press chamber 100, as shown in FIGS. 11 and 12. Once the bale 400 isvertically ejected from the bale, the crumb box 210 may be movedhorizontally so that the bumper 212 horizontally ejects the bale 400from the assembly 10. At that time, the crumb box 210 may be positonbetween the shoot 500 and the press chamber 100 and the entire processmay be repeated to form additional bales.

4.0 Exemplary Bales

Exemplary bales are shown FIGS. 8A-B, which show a low Mooney bale 400 aand high Mooney bale 400 b, respectively. As a result of performing theabove described method and using the improved baling apparatuses andbolster assemblies 308 described herein, bales 400 of rubber (or othermaterial) substantially free of imperfections and/or irregularities maybe manufactured.

5.0 Exemplary Embodiment

In one embodiment, a baling apparatus for compressing rubber materialsmay be provided. The baling apparatus may include a hydraulic rod and abolster assembly. The bolster assembly may include a first couplingportion and a second coupling portion removably attached to the firstcoupling portion. The first coupling portion and the second couplingportion may cooperatively define a cylindrical cavity for receiving thehydraulic rod, and the cavity may be between about 0.030 inches andabout 0.035 inches larger than the received portion of the hydraulicrod. The bolster assembly also may include an island portion attached tothe first coupling portion and the second coupling portion, and theisland portion may include a reduced section. A bolster cap may beattached to the island portion, and the bolster cap may include arecessed section that engages the reduced section of the island portion.The bolster cap including a plurality of countersunk bores for receivingretaining bolts that have substantially flat, rounded rectangular heads.The baler apparatus also may include a press chamber for receiving thebolster assembly and the rubber materials, wherein compression force isprovided by movement of the bolster inside the press chamber to form arubber bale.

It is contemplated that the novel portions of the baler press assembly10 could be used in any type of press assembly having a press chamber.Further, the scope of the invention is not considered limited to rubberbalers, but instead could be used in the compression of a wide varietyof materials.

While various embodiments of the invention have been described, it willbe apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible within the scope of theinvention. Accordingly, the invention is not to be restricted except inlight of the attached claims and their equivalents.

1. A baling apparatus for compressing a compressible material, thebaling apparatus comprising: a hydraulic rod; a bolster assemblyincluding a first coupling portion attached to a second couplingportion, the first coupling portion and the second coupling portioncooperatively defining a cavity for receiving a portion of the hydraulicrod; and a press chamber for receiving the bolster assembly and thecompressible material, wherein compression force is provided by movementof the bolster inside the press chamber.
 2. The baling apparatus ofclaim 1, where the bolster assembly further includes an island portionattached to the first coupling portion and the second coupling portion.3. The baling apparatus of claim 2, where the bolster assembly furtherincludes a bolster cap attached to the island portion.
 4. The balingapparatus of claim 3, where the island portion includes a reducedsection and the bolster cap includes a recessed section that engages thereduced section of the island portion.
 5. The baling apparatus of claim3, where the bolster cap includes a plurality of countersunk bores thatreceive retainer bolts.
 6. The baling apparatus of claim 5, where theretainer bolts have substantially flat heads.
 7. The baling apparatus ofclaim 6, where the retainer bolt includes a non-circular head.
 8. Thebaling apparatus of claim 5, where the retainer bolt includes asubstantially flat, rounded rectangular head attached to a frustoconicalportion.
 9. The baling apparatus of claim 8, where the diameter of abase of the frustoconical portion is smaller than a length of a side ofthe head.
 10. The baling apparatus of claim 3, where the island portionand the bolster cap have a combined weight less than 255 lbs.
 11. Thebaling apparatus of claim 1 wherein the compressible material is arubber bale.
 12. The baling apparatus of claim 1, where the firstcoupling portion defines a first arc and the second coupling portiondefines a second arc.
 13. The baling apparatus of claim 1, where thefirst coupling portion includes a first upper portion and a first lowerportion, the second coupling portion includes a second upper portion anda second lower portion, the first upper portion and the second upperportion cooperatively define a first portion of the cavity, and thefirst lower portion and the second lower portion cooperatively define asecond portion of the cavity.
 14. The baling apparatus of claim 13,where the first portion of the cavity is different from the secondportion of the cavity.
 15. The baling apparatus of claim 1, where thefirst coupling portion is removably attached to the second couplingportion.
 16. The baling apparatus of claim 1, where the cavity isbetween about 0.030 inches and about 0.035 inches larger, in ahorizontal direction than the received portion of the hydraulic rod. 17.A bolster assembly for use in a baling apparatus for compressing acompressible material, comprising: a first coupling portion; a secondcoupling portion removably attached to the second coupling portion, thefirst coupling portion and the second coupling portion cooperativelydefining a cavity for receiving a hydraulic rod, an island portionattached to the first coupling portion and the second coupling portion;and a bolster cap attached to the island portion.
 18. The bolsterassembly of claim 17, where the first coupling portion defines a firstarc and the second coupling portion defines a second arc.
 19. Thebolster assembly of claim 17, where the first coupling portion includesa first upper portion and a first lower portion, the second couplingportion includes a second upper portion and a second lower portion, thefirst upper portion and the second upper portion cooperatively define afirst portion of the cavity, and the first lower portion and the secondlower portion cooperatively define a second portion of the cavity. 20.The bolster assembly of claim 17, where the bolster cap includes aplurality of countersunk bores that receive retainer bolts that havesubstantially flat heads.
 21. The bolster assembly of claim 17, wherethe island portion and the bolster cap have a combined weight less than255 lbs.
 22. The bolster assembly of claim 17, where the cavity isbetween about 0.030 inches and about 0.035 inches larger, in ahorizontal direction than a received portion of the hydraulic rod. 23.The bolster assembly of claim 17, where the bolster cap includes aplurality of countersunk bores that receive retainer bolts, the retainerbolt including a substantially flat, rounded rectangular head attachedto a frustoconical portion.
 24. The bolster assembly of claim 23, wherethe diameter of a base of the frustoconical portion is smaller than alength of a side of the head.
 25. A method of forming a rubber bale,comprising: inserting, into a press chamber of a bale assembly,compressible rubber materials; closing the press chamber; compressing,in the press chamber, the compressible rubber materials with a bolsterassembly to form a rubber bale, the bolster assembly including: a firstcoupling portion; a second coupling portion removably attached to thesecond coupling portion, the first coupling portion and the secondcoupling portion cooperatively defining a cavity for receiving ahydraulic rod, an island portion attached to the first coupling portionand the second coupling portion; and a bolster cap attached to theisland portion, the bolster cap having a substantially flat uppersurface; opening the press chamber; and ejecting the rubber bale fromthe press chamber.
 26. A rubber bale formed by a process comprising thesteps of: inserting, into a press chamber of a bale assembly,compressible rubber materials; closing the press chamber; compressing,in the press chamber, the compressible rubber materials with a bolsterassembly to form a rubber bale, the bolster assembly including: a firstcoupling portion; a second coupling portion removably attached to thesecond coupling portion, the first coupling portion and the secondcoupling portion cooperatively defining a cavity for receiving ahydraulic rod, an island portion attached to the first coupling portionand the second coupling portion; and a bolster cap attached to theisland portion, the bolster cap having a substantially flat uppersurface; opening the press chamber; and ejecting the rubber bale fromthe press chamber.
 27. The bolster assembly of claim 19, the firstportion of the cavity is a different size than the second portion of thecavity.
 28. The bolster assembly of claim 27, where the first portion ofthe cavity is larger than the second portion of the cavity.
 29. Thebolster assembly of claim 28, where the cavity has a T-shaped crosssection for receiving a T-shaped portion of the hydraulic rod.